KR20220123514A - Lens assembly manufacturing - Google Patents

Abstract

The lens assembly includes a tube wherein an optical element, such as a lens or microlens, dispenses a volume of a curable optical polymer into the tube and attaches to the optical element using one or more plungers having a head corresponding to a desired lens curvature. Applying radiant energy to the tube by placing the plunger in place to cure the optical polymer, forming a desired shape for They are individually manufactured by repeating as necessary until the optical element is manufactured.

Description

Lens assembly manufacturing

The present invention relates to optical elements and optical systems implemented in various types of electronic systems and devices.

Lenses, microlenses and other types of optical elements are commonly included in today's mobile and wearable devices for use in imaging, virtual reality and other such applications. New opportunities exist for manufacturing lens assemblies comprising groups of optical elements aligned during manufacturing, such lens assemblies forming a single unit that can subsequently be integrated into a mobile or wearable device.

One aspect of the present invention relates to a method of making a lens assembly, the method comprising: providing a volume of a curable optical polymer to a tube; inserting a plunger into the tube, the plunger comprising a head in contact with the curable optical polymer and defining a lens curvature, the head sized to fit tightly to the inner shape of the tube. to do; curing the curable optical polymer with the plunger inserted into the tube; and removing the plunger from the tube after curing, wherein the curable optical polymer is cured into an optical element comprising a lens curvature defined by the head of the plunger.

In some embodiments, the tube is optically transparent to light of a first wavelength, and curing the curable optical polymer comprises irradiating the curable optical polymer with light of the first wavelength, Light of the first wavelength propagates through the tube to the curable optical polymer.

The head of the plunger is optically transparent to light of the first wavelength, and curing the curable optical polymer comprises light of the first wavelength propagating through the head of the plunger.

In some embodiments, the method comprises inserting a second plunger into the tube from a second end of the tube, the plunger into a first end of the tube opposite the second end of the tube. being inserted, the step of inserting; and removing the second plunger from the tube after the curing, wherein the lens curvature of the optical element is disposed on a first side of the optical element and is located opposite the first side of the optical element. and wherein the second side is defined by the second curvature of the second head of the second plunger defining a second curvature.

Curing the optical polymer includes allowing at least a portion of the optical element to bond with a portion of the inner shape of the tube.

In some embodiments, the method comprises: providing a second volume of a second curable optical polymer to the tube; inserting a subsequent plunger into the tube, the subsequent plunger including a subsequent head in contact with the second curable optical polymer and defining a second lens curvature, the subsequent head fitting tightly to the inner shape of the tube the insertion step being sized to fit; curing the second curable optical polymer with the subsequent plunger inserted into the tube; and removing the subsequent plunger from the tube after curing of the second curable optical polymer, wherein the second curable optical polymer comprises a second lens curvature defined by a subsequent head of the subsequent plunger into a second optical element. and removing said subsequent plunger, which is hardened.

The second optical element may preferably be in contact with a lens curvature of the optical element.

In some embodiments, a side of the second optical element that contacts the lens curvature of the optical element is concave, and the lens curvature of the optical element is convex.

In some embodiments, the side of the second optical element that contacts the lens curvature of the optical element is convex, and the lens curvature of the optical element is concave.

The first optical axis of the optical element is preferably axially aligned with the second optical axis of the second optical element.

In some embodiments, a lens curvature of the optical element is disposed on a first side of the optical element, and a second side of the optical element opposite the first side is defined by a lower portion of the tube do.

In some embodiments, the tube comprises a circular cross-section.

In some embodiments, the tube comprises an elliptical cross-section.

The volume of curable optical polymer may be preferably selected to provide the correct size of the optical device after curing.

Curing the curable optical polymer may preferably comprise heating the curable optical polymer using a radiant heat source external to the tube.

In some embodiments, the second curable optical polymer has a different refractive index than the first curable optical polymer.

According to a second aspect of the present invention, there is provided an image sensor; and a lens assembly configured to focus light onto the image sensor, the lens assembly comprising: a tube optically transparent to ultraviolet (UV) light of a first wavelength; a first optical element made of a volume of a UV curable optical polymer conveyed into the tube, the UV curable optical polymer having a first refractive index, and an outer boundary of the first optical element being cured in the tube. 1 optical element; and a second optical element made of a second optical polymer having a second refractive index different from the first refractive index.

Preferably, a second outer boundary of the second optical element may be hardened to the tube.

According to a third aspect of the present invention, there is provided a lens assembly comprising: a tube optically transparent to light of a first wavelength; An optical device, wherein the optical device is made of a volume of an optical polymer conveyed into the tube, the volume of optical polymer is bonded to the inner shape of the tube, and wherein the volume of optical polymer has a first index of refraction. , the optical element; and at least one other optical element, wherein the at least one other optical element is made of a second optical polymer carried into the tube and bonded to the inner shape of the tube, the second optical polymer having a second index of refraction; said at least one other optical element.

In some embodiments, the tube is transparent to ultraviolet light and the first wavelength of the light is in the ultraviolet range.

BRIEF DESCRIPTION OF THE DRAWINGS Non-limiting and non-exclusive embodiments of the present invention are described with reference to the following drawings in which like reference numerals indicate like parts through various aspects, unless otherwise specified.
1 is a perspective view of a head mounted display (HMD) in which a lens assembly manufactured according to an embodiment of the present invention is integrated.
2A is a front view of system elements that may be used to fabricate a lens assembly, in accordance with one embodiment of the present invention.
2B is a top cross-sectional view of a tube that may be used to fabricate a lens assembly, in accordance with one embodiment of the present invention.
3A-3D are front views of system elements in use during manufacture of a first optical element of a lens assembly, in accordance with an embodiment of the present invention;
4A-4D are front views of system elements in use during manufacture of a second optical element of a lens assembly, in accordance with an embodiment of the present invention;
5 is a front view of a partially constructed lens assembly with a third optical element, in accordance with an embodiment of the present invention.
6 is a front view of a partially constructed lens assembly with a fourth optical element, in accordance with an embodiment of the present invention.
7A is a front view of a finished lens assembly including six optical elements, according to an embodiment of the present invention.
7B is a front view of a complete lens assembly with optional protective elements at each end of the assembly, in accordance with one embodiment of the present invention.
8 illustrates an operational flow associated with a method of manufacturing a lens assembly, in accordance with an embodiment of the present invention.

Embodiments of an apparatus, system, and method for manufacturing a lens assembly are described herein. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments. However, those skilled in the relevant art will recognize that the techniques described herein may be practiced without one or more of the specific details, or using other methods, components, materials, and the like. In other instances, well-known structures, materials, or works have not been shown or described in detail in order to avoid obscuring certain aspects.

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. do. Thus, the appearances of the phrases "in one embodiment" or "in one embodiment" in various appearances throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the specific features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

Apparatus, systems and methods for making the lens assemblies described herein include a tube into which a precise volume of the curable optical polymer is delivered. A volume of optical polymer is bound by at least one plunger inserted into the tube, the plunger having a lens curvature that causes the optical polymer adjacent the plunger to assume a shape defined by the curvature. Radiant energy is applied to the tube and polymer from the outside of the tube. Radiant energy is transmitted to the tube to cure the polymer, causing the polymer to form a rigid optical device. The plunger is then removed from the tube, leaving the rigid optical element with the aforementioned lens curvature. One or more additional optical elements may be formed in the tube through successive operations of inserting the polymer into the tube, engaging the polymer with a plunger having the desired lens curvature, and curing the polymer. Thus, the resulting lens assembly is configured in an advantageous manner such that the optical elements within the tube can be coaxially aligned along the optical axis of the individual elements, wherein the tube is connected to a virtual reality system, head mounted display or other mobile or wearable device. It can be easily integrated as a single lens assembly component of the device. These and other embodiments are described in greater detail with respect to FIGS. 1-8 .

1 is a perspective view of a head mounted display (HMD) 100 with an integrated lens assembly, according to an embodiment of the present invention. The described example of the HMD 100 is shown to include a viewing structure 140 , an upper anchoring structure 141 , a side anchoring structure 142 , a rear anchoring structure 143 , and an anterior rigid structure 144 . . In some examples, the HMD 100 may be configured to be worn on the head of a user of the HMD 100 , and the upper fixing structure 141 , the side fixing structure 142 , and/or the rear fixing structure 143 . ) may include a fabric strap including an elastic and one or more rigid structures (eg, plastic) for fixing the HMD 100 to the user's head. HMD 100 may also optionally include one or more earpieces 120 for delivering audio to the ear(s) of a user of said HMD 100 .

The described example of the HMD 100 also includes an interface membrane 118 for contacting the face of a user of the HMD 100 , the interface membrane 118 allowing at least some ambient light to pass through the HMD 100 . It functions to block it from reaching the user's eyes.

The example HMD 100 may also include a chassis to support hardware of the viewing structure 140 of the HMD 100 (the chassis and hardware not explicitly shown in FIG. 1 ). The hardware of observation structure 140 may include processing logic, wired and/or wireless data interfaces for transmitting and receiving data, a graphics processor, and one or more memory for storing data and computer-executable instructions. In one example, viewing structure 140 may be configured to receive wired power and/or may be configured to be powered by one or more batteries. Additionally, viewing structure 140 may be configured to receive wired and/or wireless data including video data.

In some examples, an eye tracking camera (not explicitly shown in FIG. 1 ) may be included in the viewing structure 140 to capture image(s) of the HMD 100 user's eye. The viewing structure 140 may also include a display system having one or more electronic displays for directing light to the eye(s) of the HMD 100 user. The display system may include one or more of an LCD, an organic light emitting diode (OLED) display, or a micro LED display for emitting light (eg, content, images, video, etc.) to the HMD 100 user.

HMD 100 may include an integrated lens assembly 150 oriented to work with image sensor 152 to focus an image having particular image characteristics onto an image plane. The integrated lens assembly 150 includes at least one optical element having a refractive index corresponding to a desired image characteristic. In some embodiments, the integrated lens assembly has two or more optical elements within a tube, the optical elements positioned opposite each other and coaxially aligned along the optical axis of the individual elements. The HMD is an example of a device in which the integrated lens assembly 150 may be included. However, the integrated lens assembly 150 may be integrated into any device.

2A and 2B are views of a tube 202 in which the optical elements are individually fabricated to provide a framework for transforming the tube 202 and fabricated optical elements into the lens assembly 150 discussed with respect to FIG. 1 . It is a front view and a plan cross-sectional view. The cross-section of the tube 202 may be circular or the cross-section may depend on the desired cross-sectional shape of the optical elements formed within the tube 202 and/or a cavity in a device such as HMD 100 that will receive the lens assembly. Depending on the shape, it may have an elliptical or other profile (eg, square, rectangular, etc.). In some embodiments, the tube 202 is optically transparent to at least some wavelengths of light. Such wavelengths may include one or more of ultraviolet (UV) light, infrared (IR) light, or other wavelengths of light. In other embodiments, the tube 202 allows heat to pass through the side of the tube 202 . The tube 202 may be constructed of glass, plastic, or other material having the desired transparency properties, and may be open at one or both ends. In some embodiments, the tube 202 may be divided such that the vertical segments of the tube 202 have different shapes. For example, the tube 202 may have a stepped shape in which the diameter of the first cylindrical tube cross-section may be different from the diameter of the second cylindrical tube cross-section. The stepped shape may aid in the creation of optical elements formed within the tube 202 having various diameters. Alternatively, tube 202 may have one or more tapering characteristics. For example, the tube 202 may be wider at the top and narrower at the bottom due to a taper that tapers from the top to the bottom of the tube 202 . The taper may also aid in the creation of optical elements formed within the tube 202 having various diameters. Alternatively, the stepped shape or taper of the tube 202 may provide a specific shape for the finished lens assembly that meets the needs of the device in which the lens assembly will be placed.

The tube 202 is held in place vertically by a fixture (not shown) and is vertical (eg, the sides of the tube 202 are parallel to gravity). A first plunger 206 may be inserted into the tube 202 from a lower end of the tube 202 . The first plunger 206 includes a first plunger head 208 . The first plunger head 208 may include a cavity, the curvature of the cavity defining a desired lens curvature 209 for the lower surface of the first optical element fabricated in the assembly. While the cavity of the first plunger head 208 shown in the figures is concave with respect to the top of the tube, the first plunger head 208 may be concave or concave depending on the specific curvature requirements for the first optical element of the desired lens assembly. It may be convex or have other shapes. For example, in some aspects the curvature provided by the plunger head is constant across the surface such that the surface can be referred to as a sphere. The concave or convex plunger head cavity can provide the constant curvature described above. In other aspects, the curvature may be an aspherical surface with varying curvature across the surface, and a correspondingly shaped plunger head may be provided. The curvature provided by the plunger head is not necessarily rotationally symmetric. In another aspect, the plunger head 208 may include a diffractive structure for forming a diffractive optical element. The plunger head 208 is sized to fit tightly to the inner shape of the tube 202 (ie, the plunger head 208 has a perimeter against the inner sidewall 220 of the tube 202 ). and having an outer boundary slightly smaller than the inner boundary of the tube 202, etc.). Alternatively, the lower surface of the tube 202 may be closed such that the lower surface of the first optical element manufactured in the assembly is flat. The inner sidewall 220 is disposed opposite the outer sidewall 230 (ie, the outer sidewall 230 is disposed along the outer wall of the tube 202 ).

Referring to FIG. 3A , a volume of curable optical polymer 314 is provided into the tube 202 . A source, such as a syringe (not shown), is controlled to dispense the correct volume of optical polymer that is dropped or otherwise delivered into the tube. If the polymer is comprised of one or more droplets (such as, for example, polymer droplets 314A, 314B, 314C shown in FIG. 3A ), upon landing on the defrost first plunger head 208, the polymer droplets coalesce to form a single form a volume The tight fit of the plunger head 208 to the inner shape of the tube 202 causes any optical polymer 314 transported into the tube 202 to remain within the tube 202 (ie, optical polymer). ensure that no portion of 314 flows out through the bottom of the tube 202 past the plunger 206).

As shown in FIG. 3B , when a volume of curable optical polymer 314 is placed over the head 208 of the first plunger 206 , the second plunger 310 moves into the top of the tube 202 . is inserted The second plunger 310 includes a second plunger head 312 . The second plunger head 312 may include a cavity. The curvature of the cavity may define a desired lens curvature 313 for the upper surface of the first optical element fabricated in the assembly. Whereas the cavity of the second plunger head 312 shown in the figures is concave relative to the bottom of the tube, the second plunger head 312 may be concave or convex.

3c, the second plunger 310 is contacted with a volume of curable optical polymer such that the volume matches the curvature of the first and second plunger heads 208, 312; It takes the desired shape for the optical element 320 . Like the first plunger head 208, the second plunger head 312 is sized to fit snugly to the inner shape of the tube 202, so that a precisely measured volume of optical polymer is transferred to the plunger head. 312) and the side of the tube. The curing operation occurs while the second plunger 310 is in the tube 202 , which may include radiant energy 318 passing through the tube 202 , the radiant energy 318 being energy emanating from the source 316 . In some embodiments, the radiant energy 318 is light having a specific wavelength selected to propagate through the tube 202 to illuminate the volume of curable optical polymer, and the energy source 316 is a specific It is an emitter of light having a wavelength. For example, the energy source 316 may be an ultraviolet lamp or LED, and the radiant energy 318 may be light corresponding to ultraviolet light, an ultraviolet lamp, and particularly an optical polymer reactive to ultraviolet light. In another embodiment, the radiant energy 318 is thermal energy that propagates through the tube 202 and is selected to heat the volume of curable optical polymer. The radiant energy 318 may also propagate through the first plunger head 208 and/or the second plunger head 312 via light or heat. The curing operation may include stopping or reducing thermal energy as radiant energy 318 to allow the optical element 320 to cool and cure.

As shown in FIG. 3D , the second plunger 310 is removed from the tube 202 after a curing operation. During a curing operation, the optical polymer is cured to retain its molded shape when the second plunger 310 is removed from the tube 202 . After removal of the second plunger 310 from the tube 202 , the cured optical polymer remains in the tube 202 and the upper lens curvature defined by the head 312 of the second plunger 310 . An optical element 320 including 313 is formed. In some embodiments, the optical polymer may shrink during curing. To account for changes in the volume of the polymer while still obtaining an optical element of the desired curvature and size, the plunger head size or shape takes into account the expected shrinkage of the given volume of optical polymer according to the known shrinkage properties of the particular optical polymer in use. selected and/or adapted to In some aspects, plunger head 208 and/or plunger head 310 imparts a diffractive structure within the optical polymer to form a diffractive optical element as optical element 320 .

In some embodiments, at least a portion of the optical element 320 remains adhered to the inner sidewall of the tube 202 after removal of the second plunger 310 . For example, the outer boundary or ring 315 of the optical element 320 in contact with the interior of the tube 202 may result in the inner sidewall of the tube (ie, the interior as shown in FIG. 2B ) as a result of the curing operation. The sidewall 220 may be bonded to the interior of the tube 202 . The bonding of the ring 315 around the optical element 320 to the interior of the tube created during curing remains in place after the optical element is attached to the tube 202 and the second plunger 310 is removed. can make it possible The portion of the ring 315 of the optical element 320 that is coupled to the tube 202 during the curing operation is such that, for example, upon insertion of the second plunger 310, the optical polymer is absorbed into the interior of the tube 202 . This can result in precisely metering only enough optical polymer into tube 202 to flow in a thin stream up to the sidewall.

4A to 4D illustrate a front view of the tube 202 in which the first optical element 320 is present. In a subsequent operation, the fabrication of a second optical element on top of the first optical element takes place. As shown in FIG. 4A , a volume of curable optical polymer 414 is provided in the tube 202 . The curable optical polymer 414 may be the same material discussed with respect to FIG. 3A (ie, it may be the same material as the curable optical polymer 314 provided in the tube for manufacturing the first optical element 320 ). have). Alternatively, the curable optical polymer 414 may have different optical properties, such as different refractive indices, different corresponding light wavelengths or corresponding temperatures for curing, and the like. The polymer may be composed of one or more droplets, such as polymer droplets 414A, 414B, and 414C shown in FIG. 4 , which may coalesce upon landing to form a single volume.

As shown in FIG. 4B , when the volume of curable optical polymer 414 is placed over the top surface of the first optical element 320 , a subsequent plunger 410 is inserted into the top of the tube 202 . . The subsequent plunger 410 includes a plunger head 412 , which may include a surface defining a desired lens curvature 413 for the upper surface of the second optical element. The surface of the plunger head 412 may be concave or convex depending on the specific needs of the upper surface of the second optical element of the desired lens assembly. (The plunger head 412 is shown concave with respect to the bottom of the tube in FIGS. 4B-4D ).

As shown in FIG. 4C , the subsequent plunger 410 is in contact with the volume of curable optical polymer 414 so that the volume assumes the desired shape for the second optical element 420 . to conform to the curvature of the upper surface of the optical element 320 and the curvature 413 of the subsequent plunger head 412 . Another curing operation occurs while the subsequent plunger 410 is in the tube 202 , which may include radiant energy 418 passing through the tube 202 , the radiant energy 418 being the energy emitted from the source. The radiant energy 418 may have the same or different wavelengths or other radiant properties as desired to correspond to the curing requirements of the curable optical polymer 414 . The subsequent plunger head 412 may have the same curvature 413 as the head of the first and second plungers described with respect to FIGS. 3A-3D, or may have a different curvature 413, Thereby the difference of optical elements made with various plungers having the same curvature can be influenced, for example, through the use of optical polymers with different refractive indices.

As shown in FIG. 4D , the subsequent plunger 410 is removed from the tube 202 after the curing operation. After removal of the subsequent plunger (410) from the tube (202), the cured optical polymer remains in the tube, forming a second optical element (420) in contact with the top of the first optical element (320); , the second optical element 420 includes a lower lens curvature that is the inverse of the upper lens curvature of the first optical element 320 and an upper lens curvature defined by the head 412 of the subsequent plunger 410 ( 413). The optical axes of the first optical element 320 and the second optical element 420 are aligned as a result of fabrication operations occurring within a circular cross-section tube held in place vertically by a fixture.

In some embodiments, at least a portion of the second optical element 420 remains attached to the inner sidewall of the tube 202 after removal of the subsequent plunger 410 . The attachment of the second optical element 420 to the inner sidewall of the tube 202 is the same as the attachment of the first optical element 320 to the inner sidewall of the tube 202 described above with respect to FIG. 3D . may occur in substantially the same way.

The attachment of successive optical elements to the inner sidewall of the tube 202 aligns the successive optical elements along each of the optical axes of the other optical elements. Thus, as a result of manufacturing the optical elements inside the tube 202 such that the outer boundary of the optical elements is coupled to the corresponding inner sidewall of the tube 202 , the optical elements when fabricated in the tube 202 are It has a coaxial optical axis.

5 , a partially constructed lens assembly is shown according to another set of operations similar to that shown in FIGS. 3A-3D and 4A-4D . That is, a volume of optical polymer, which rests on the upper surface of the optical element 420, was provided to the tube 202; a plunger 510 is inserted into the tube 202 such that the plunger head 512 is in contact with the volume of optical polymer; hardening occurs; The plunger 510 is removed from the tube 202 following the predetermined optical polymer to cure, resulting in a lower lens curvature defined by the upper surface of the optical element 420 with a third optical element 520 . and an upper lens curvature 513 defined by the cavity of the plunger head 512 of the plunger 510 . In this exemplary embodiment, the plunger head 512 is convex with respect to the lower portion of the tube 202 , although in other embodiments the plunger head 512 may be configured to be concave or convex as desired. In this case, the optical device can be manufactured with desired optical properties.

6 , a partially constructed lens assembly is shown according to another set of operations similar to those shown in FIGS. 3A-3D and 4A-4D . In particular, through a series of operations thereof, a fourth optical element 620 is formed in the tube 202 , and the fourth optical element 620 has a lower lens curvature defined by an upper surface of the optical element 520 . and an upper lens curvature 613 defined by the cavity of the plunger head 612 of the plunger 610 .

Referring to FIG. 7A , there is shown a finished lens assembly 150 from which a fifth optical element 720 and a sixth optical element 722 are fabricated. The first plunger is also shown removed from the tube 202 . However, since in some embodiments the first optical element may be removed at any time after manufacture, no inference should be drawn that it is necessary to leave the plunger in place until after all the optical elements have been manufactured. . For example, the first optical element 320 may be attached to the inner sidewall of the tube 202 when manufactured as shown in FIGS. 3A to 3D . Accordingly, upon curing of the first optical element 320 , removal of the lower plunger in place during the curing operation can be achieved. Also, although the lens assembly 150 discussed herein features six optical elements in a stack within the tube, the disclosed techniques may be applied to create a lens assembly having any number of optical elements.

Referring to FIG. 7B , a completed lens assembly 150 is shown, on top of which an optional protective element 702a is provided in the assembly discussed with respect to 7a, and on its bottom an optional protective element 702b . provided in the assembly. The optional protective elements may be constructed of glass, plastic or other transparent material and may be optically neutral or nearly neutral so as not to adversely modify the desired optical properties created by the stack of optical elements in the tube 202 . . Similarly, during construction of the lens assembly, other elements may be inserted into the tube 202 between fabrication of optical elements. Such elements may include windows, apertures, preformed glass or plastic elements. In some embodiments, diffractive optical elements may be included in the lens assembly 150 . Separating the optical elements fabricated inside the tube 202 using the aforementioned windows, apertures, preformed glass or plastic elements, voids between lens surfaces, apertures between lens surfaces, and e.g. bonded doublets or the inclusion of glass elements or assemblies to provide other arrangements. In some embodiments, the various optical elements of the lens assembly 150 are not necessarily rotationally symmetric or light having an optical axis shared by the other optical elements of the lens assembly 150 .

The finished lens assembly 150 may be fabricated directly over the image sensor. This may contribute to miniaturizing the space required for the lens assembly to be paired with the image sensor. In an aspect, a lens assembly, such as lens assembly 150, may be fabricated over an image sensor for which the lens assembly has a nominal focal length. A camera comprising a specific image sensor paired with a specific lens assembly through focus measurement (eg, analyzing digital images captured by the image sensor while the lens assembly focuses light onto the imaging plane of the image sensor) An adjusted optical power value can be determined to improve the focus of . The lens assembly can then be adjusted according to the adjusted optical power value to improve the focus of the lens assembly. In one example, the lens assembly is adjusted by adjusting the upper radius of curvature of an optical element, such as optical element 722 .

In some embodiments, after completion of a lens assembly according to operations disclosed herein, the tube may be coated to prevent light from entering the finished lens assembly from the side of the tube 202 . In some embodiments, coating may include spraying or painting the tube 202 with, for example, a black and/or absorbent layer. In other embodiments, removing the tube 202 from the lens assembly stack may occur to reduce the diameter of the finished lens assembly.

8 depicts an operational flow 800 of a method of manufacturing a lens assembly, in accordance with one embodiment of the present invention. The integrated lens assembly 150, prior to being integrated with the HMD 100, in step 802 (discussed in greater detail above with respect to FIG. 3A ), may include: providing a volume of a volume of curable optical polymer to the tube; In step 804 (discussed in more detail above with respect to FIGS. 3B and 3C , above), inserting a plunger into the tube, the plunger comprising a head in contact with the curable optical polymer and defining a lens curvature, wherein the head is sized to fit snugly to the inner shape of the tube; in step 806 (discussed in greater detail above with respect to FIGS. 3B and 3C ), curing the curable optical polymer with the plunger inserted into the tube; and in step 808 (above, discussed in greater detail with respect to FIG. 3D ), removing the plunger from the tube after curing, wherein the curable optical polymer comprises a lens curvature defined by the head of the plunger. It can be manufactured by removing the plunger, which is hardened into a device.

The order in which some or all of the process blocks appear in process 800 should not be considered limiting. Rather, it will be appreciated by those skilled in the art having the benefit of the present invention that some of the above processes may be performed in various orders not shown or in parallel.

Embodiments of the present invention may include or be implemented with an artificial reality system. Artificial reality may include, for example, virtual reality (VR), augmented reality (AR), mixed reality (MR), hybrid reality, or some combination and/or derivative thereof in any way prior to presentation to the user. It is a form of adjusted reality. Artificial reality content may include fully generated content or generated content combined with captured (eg, real world) content. The artificial reality content may include video, audio, haptic feedback, or some combination thereof, any of which is provided as a single channel or multiple channels (eg, stereo video that creates a three-dimensional effect for the viewer). can be Additionally, in some embodiments, artificial reality is also used, for example, to generate content in and/or otherwise used in artificial reality (eg, performing an activity in artificial reality); It may be associated with an application, product, accessory, service, or some combination thereof. The artificial reality system providing the artificial reality content may include a head mounted display (HMD) coupled to a host computer system, a standalone HMD, a mobile device or computing system, or any other hardware capable of providing artificial reality content to one or more viewers. It can be implemented on a variety of platforms, including platforms.

The foregoing description of illustrated embodiments of the invention, including what is described in the Abstract, is not intended to be exhaustive or to limit the invention to the precise form disclosed. Although specific embodiments and uses of the invention have been described herein for purposes of illustration, various modifications are possible within the scope of the invention, as those skilled in the relevant art will recognize.

Such modifications may be applied to the present invention in light of the above detailed description. The terms used in the following claims should not be construed as limiting the invention to the specific embodiments disclosed herein. Rather, the scope of the invention should be determined solely by the following claims, which should be construed in accordance with established doctrines of claim interpretation.

Claims (15)

A method of making a lens assembly comprising:
providing a volume of the curable optical polymer to the tube;
inserting a plunger into the tube, the plunger comprising a head in contact with the curable optical polymer and defining a lens curvature, the head sized to fit tightly to the inner shape of the tube. to do;
curing the curable optical polymer with the plunger inserted into the tube; and
removing the plunger from the tube after curing, wherein the curable optical polymer is cured into an optical element comprising a lens curvature defined by the head of the plunger. The method of claim 1 , wherein the tube is optically transparent to light of a first wavelength, and curing the curable optical polymer comprises irradiating the curable optical polymer with light of the first wavelength, and wherein wherein light of a first wavelength propagates through the tube and into the curable optical polymer. 3. The method of claim 2, wherein the head of the plunger is optically transparent to light of the first wavelength, and wherein curing the curable optical polymer comprises light of the first wavelength propagating through the head of the plunger. , Way. 4. The method according to any one of claims 1 to 3,
inserting a second plunger into the tube from a second end of the tube, the plunger being inserted into a first end of the tube opposite the second end of the tube; and
removing the second plunger from the tube after the curing, wherein the lens curvature of the optical element is disposed on a first side of the optical element, the second of the optical element being opposite the first side The method further comprising the step of removing, wherein a side surface is defined by the second curvature of the second head of the second plunger defining a second curvature. 5. The method of claim 4, wherein curing the optical polymer comprises allowing at least a portion of the optical element to bond with a portion of the inner shape of the tube. 6. The method according to any one of claims 1 to 5,
providing a second volume of a second curable optical polymer to the tube;
inserting a subsequent plunger into the tube, the subsequent plunger including a subsequent head in contact with the second curable optical polymer and defining a second lens curvature, the subsequent head fitting tightly to the inner shape of the tube the insertion step being sized to fit;
curing the second curable optical polymer with the subsequent plunger inserted into the tube; and
removing the subsequent plunger from the tube after curing of the second curable optical polymer, wherein the second curable optical polymer is cured to a second optical element comprising a second lens curvature defined by a subsequent head of the subsequent plunger wherein the method further comprises removing the subsequent plunger, preferably the second optical element is in contact with the lens curvature of the optical element. 7. The method according to claim 6, wherein a side surface of the second optical element contacting the lens curvature of the optical element is concave, and the lens curvature of the optical element is convex; or preferably the side of the second optical element contacting the lens curvature of the optical element is convex and the lens curvature of the optical element is concave. 7. The method of claim 6, wherein a first optical axis of the optical element is axially aligned with a second optical axis of the second optical element. 9. The method according to any one of claims 1 to 8, wherein a lens curvature of the optical element is disposed on a first side of the optical element, and a second side of the optical element opposite the first side is the defined by the bottom of the tube. 10. The method according to any one of claims 1 to 9, wherein the tube comprises a circular cross-section; or preferably the tube comprises an elliptical cross-section. 11. The method of any one of claims 1-10, wherein the volume of curable optical polymer is selected to provide the correct size of the optical device after curing; and/or preferably curing the curable optical polymer comprises heating the curable optical polymer using a radiant heat source external to the tube; and/or preferably the second curable optical polymer has a different refractive index than the first curable optical polymer. image sensor; and
a device comprising a lens assembly configured to focus light onto the image sensor, the device comprising:
The lens assembly comprises:
a tube optically transparent to ultraviolet (UV) light of a first wavelength;
a first optical element made of a volume of a UV curable optical polymer conveyed into the tube, the UV curable optical polymer having a first refractive index, and an outer boundary of the first optical element being cured in the tube. 1 optical element; and
a second optical element made of a second optical polymer having a second index of refraction different from the first index of refraction. 13. The device of claim 12, wherein a second outer boundary of the second optical element is cured to the tube. A lens assembly comprising:
a tube optically transparent to light of a first wavelength;
An optical device, wherein the optical device is made of a volume of an optical polymer conveyed into the tube, the volume of optical polymer is bonded to the inner shape of the tube, and wherein the volume of optical polymer has a first index of refraction. , the optical element; and
at least one other optical element, wherein the at least one other optical element is made of a second optical polymer carried into the tube and bonded to the inner shape of the tube, the second optical polymer having a second index of refraction; A lens assembly comprising at least one other optical element. 15. The lens assembly of claim 14, wherein the tube is transparent to ultraviolet light and the first wavelength of light is in the ultraviolet range.

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